Thermadyne Thermal Dynamics PAK MASTER 50XL Service Manual Download Page 55 | Manualshive

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Manual 0-2587

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Summary of Contents for Thermal Dynamics PAK MASTER 50XL

Page 1: ...Manual No 0 2587 August 11 1999 PAK MASTER 50XL Air Plasma Cutting Power Supply Service Manual A 01324...

Page 2: ......

Page 3: ...mal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1997 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or...

Page 4: ...ies 12 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 13 4 01 Introduction 13 4 02 Periodic Inspection Procedures 13 4 03 Common Operating Problems 13 4 04 Troubleshooting Guide General Information 14...

Page 5: ...de Internal Component Replacement Parts List 48 6 09 Options and Accessories 50 APPENDIX I INPUT WIRING REQUIREMENTS 51 APPENDIX II SEQUENCE OF OPERATION BLOCK DIAGRAM 52 APPENDIX III POT LED PC BOARD...

Page 6: ......

Page 7: ...ep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the ki...

Page 8: ...yes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from...

Page 9: ...uit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sul...

Page 10: ...9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE ET EXPLOSION Les incendies et les explos...

Page 11: ...ashington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l InstitutAm ricain des Normes Nationales Ameri can National...

Page 12: ...LAPR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2...

Page 13: ...andardsAssociation standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 9...

Page 14: ...roducts shall be as follows with the exception of XL Plus Series CutMaster 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 yea...

Page 15: ...ill assure obtaining the performance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Ap...

Page 16: ...INTRODUCTION 10 Manual 0 2587...

Page 17: ...figurations Machine torches are available only in Model PCM 28 and include a rack and pinion mounting assem bly Torch leads are available in 25 ft 7 6 m or 50 ft 15 2 m lengths with fittings for simpl...

Page 18: ...ter is available The filter will remove moisture and contaminants from the air stream when using compressed air The filter is capable of filtering to at least 5 microns The filter assembly is pre asse...

Page 19: ...ng Piloting is harder on parts life than actual cutting be cause the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to...

Page 20: ...not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques A Troubleshooting and Repair Troubleshooting and repair of this unit is...

Page 21: ...ven to iden tify the possible symptom s and the defective circuit After repairs are complete then run the following tests again to verify that the unit is fully operational A Initial Setup Conditions...

Page 22: ...closed a Close main power disconnect 3 Main power line fuses blown a Replace main power line Fuses 4 Defective input power cable a Replace input power cable 5 Improper input power line connections ins...

Page 23: ...inuity on Logic Ribbon Cable from J4 10 Logic PC Board to J6 10 FET Heatsink As sembly If cable has open replace ribbon cable If cable has continuity replace FET Heatsink Assembly 2 Defective Logic PC...

Page 24: ...continuity 3 Faulty Logic or Pilot PC Board Disconnect the Torch Control Cable from the J22 connector Check for dc voltage from Logic PC Board J5 pin 8 to J5 pin 9 a Replace Logic PC Board if voltage...

Page 25: ...indicator blinks Small arc may be visible in torch 1 Faulty Pilot Output PC Board or Shorted Torch a Test per Section 4 09 H repair as necessary 2 Faulty FET Heatsink Assembly a Check per Section 4 0...

Page 26: ...indicators inside the Power Supply Pilot indicator D33 on the Logic PC Board is ON during pilot then OFF during main arc transfer CSR indicator D31 on the Logic PC Board is OFF during pilot then ON du...

Page 27: ...l 4 Close the enclosure by reversing the above steps C Diode Testing Basics Testing of diode modules requires a digital volt ohmme ter that has a diode test scale Remember that even if the diode modul...

Page 28: ...R2 AC2 Open AC3 R2 Diode Drop R2 AC3 Open AC1 Open AC1 Diode Drop AC2 Open AC2 Diode Drop AC3 Open AC3 Diode Drop The meter should indicate a diode drop in one direction and an open in the other dire...

Page 29: ...ssembly 3 Place the front panel ON OFF switch to ON 4 Check status of the TEMP indicator If indicator has gone OFF then remove power and replace the Upper FET Heatsink Assembly 5 Place the front panel...

Page 30: ...f shorted remove the wires at E23 and E24 at the Pi lot Output PC Board and check again Replace Pilot Output PC Board if shorted from E23 to E24 with wires 17 and 16 removed I FET Heatsink Circuit Tes...

Page 31: ...indicating a problem exists the Logic PC Board sends a signal which turns OFF the PWM Enable signal to the Gate Drive PC Board Because this happens in less than 50 milliseconds it is not easy to take...

Page 32: ...NING Connector J11 on the CD PC Board must be dis connected to prevent electrical damage to measur ing equipment when testing the open circuit volt age OCV c Press and hold the hand torch switch Logic...

Page 33: ...meter lead on gate lead of Q6 and meter lead on source lead of Q6 The meter should indicate approximately 2 5K ohms f Place the meter lead on drain lead of Q6 and meter lead on source lead of Q6 The...

Page 34: ...embly to check the output rectifier reverse bias The meter should indicate OL using the diode function or 100K ohms using the ohms function f Place the meter lead on E18 and the meter lead on the heat...

Page 35: ...from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist...

Page 36: ...ove procedure noting the following Leads Wrap must be installed on the replace ment Left Side Panel before panel is installed Place the Left Side Panel onto the frame and slide the top edge under the...

Page 37: ...pointer on the knob 2 Loosen the screw securing the Current Knob to the potentiometer shaft 3 Remove the Current Knob 4 Unlatch the Access Panel to gain access to the Pot LED PC Board 5 Remove the Po...

Page 38: ...nel to Base Front Assembly d On the right side remove the two screws secur ing the Pilot Panel to the Base Front Panel Assembly e On the right side remove the three nuts and washers securing the inter...

Page 39: ...standoffs 4 Remove the Work Cable per the following a Remove Right Side Panel per Section 5 04 C b Loosen the Work Cable end at the terminal on the Output PC Board c Remove the Work Cable end from the...

Page 40: ...s part is an option and may not be installed on all units 1 Disconnect the gas supply hose from the IN side of the Two Stage Filter Assembly 2 Pull the Two Stage Filter Assembly out of the mounting br...

Page 41: ...Disconnect all the wiring connections to the Pilot Output PC Board Assembly 3 Remove the four screws and washers securing the PC Board to the standoffs 4 Install the replacement Pilot Output PC Board...

Page 42: ...acement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Right Side Panel per Section 5 04 C 3 Disconnect the single pin connector on the white wire coming from the Auxiliary Transformer A...

Page 43: ...Side Internal Component Replacement Parts List Section 6 09 Options and Accessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a...

Page 44: ...ANDLE 1 125 OD 11 85 LG 9 7505 2 2 MOUNT LIFTING HANDLE 9 7506 3 1 COVER LEFT SIDE Includes 9 7583 COVER LEFT SIDE LABEL USER WARNING ENGLISH 4 1 COVER RIGHT SIDE Includes 9 7584 COVER RIGHT SIDE OVER...

Page 45: ...Manual 0 2587 39 PARTS LISTS A 01381 2 1 3 4 5 2...

Page 46: ...C Current Pot Shaft Diameter 1 8 inch Order Kit 9 7014 Current Pot Shaft Diameter 1 4 inch Knob Only 9 8007 3 1 ON OFF ROCKER SWITCH DPST 8 3258 4 1 SWITCH ROCKER SPST 9 1042 5 1 PANEL ACCESS Includes...

Page 47: ...Manual 0 2587 41 PARTS LISTS A 01065 1 2 3 4 5 6 7 8...

Page 48: ...BASE FRONT UNIT Includes 9 7587 BASE FRONT UNIT GROUND TAG 8 4243 USA LABEL 1 3 4 X 3 8 3216 OVERLAY FRONT PANEL 9 7593 2 1 CONTACTOR 3 POLE 40 FLA 600 VAC 9 7554 3 1 STRAIN REFIEF FOR 10 STRANDED WI...

Page 49: ...Manual 0 2587 43 PARTS LISTS A 01382 2 4 1 3 5...

Page 50: ...FET HEATSINK Includes 9 7560 ASSEMBLY FET HEATSINK 7 DUST COVER FET ASSEMBLY 8 1 FUSE BLOCK 9 5562 9 1 FUSE 0 8A 600V 13 32 DIA 9 7526 10 1 BUSHING See Note 1 11 1 LABEL VOLTAGE SELECTION See Note 1 1...

Page 51: ...Manual 0 2587 45 PARTS LISTS To Input PCB To J10 On Logic PCB A 01420 1 15 9 8 11 17 10 16 13 14 7 6 6 2 7 2 3 4 5 12 12 12 12 J10...

Page 52: ...1 8 NPT X 1 4 TUBE 90 9 7525 10 1 PRESSURE GAUGE 9 1045 11 1 PANEL REAR Includes 9 7588 PANEL REAR LABEL GAS SUPPLY LABEL INPUT POWER CONNECTIONS 12 1 BRACKET REGULATOR MOUNTING 9 7589 13 2 10 32X 5 P...

Page 53: ...Manual 0 2587 47 PARTS LISTS A 01068 1 6 2 14 12 16 10 15 9 8 7 3 5 5 4 13 17 11...

Page 54: ...1 BRACKET BULKHEAD MOUNTING See Note 1 6 1 INSULATOR BULKHEAD See Note 1 7 1 PCR RELAY DPST NO 25A 250V 12VDC COIL 9 7508 8 1 TRANSFORMER AUX IEC BOBBIN 9 7541 9 1 ASSEMBLY MAIN TRANSFORMER 9 7567 10...

Page 55: ...Manual 0 2587 49 PARTS LISTS A 01383 14 6 2 11 13 15 7 12 3 8 10 9 4 1 5...

Page 56: ...ories Qty Description Catalog 1 Smart Cart 7 7777 Interface Cable For Use With Machine Torches Only 1 25 foot 7 62m 8 5557 1 50 foot 15 24m 8 5558 1 575V Transformer 9 7500 1 220V Single Phase Input P...

Page 57: ...rotection and W ire S izes B ased on National E lectric Code and Canadian E lectrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirement...

Page 58: ...orch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to syst...

Page 59: ...rrent Control from Logic PC Board J3 9 J14 4 12 VDC from Logic PC Board J3 10 J14 5 Signal for AC OK Indicator to Logic PC Board J3 11 J14 6 Signal for GAS Indicator to Logic PC Board J3 12 J14 7 Sign...

Page 60: ...tch J2 15 Over Temperature Switch on Input Bridge J2 16 Over Temperature Switch Return J3 1 36 VAC to ON OFF Switch J3 2 36 VAC from ON OFF Switch to Logic PC Board J3 3 36 VAC to ON OFF Switch J3 4 3...

Page 61: ...Board J9 17 J4 18 Demand Signal to Gate Drive PC Board J9 18 J4 19 Return for Demand to Gate Drive PC Board J9 19 J4 20 Not Used J5 1 36 VAC to CD PC Board J11 1 J5 2 Return to CD PC Board J11 2 J5 3...

Page 62: ...nt Sense from FET PC Boards J6 7 J7 8 Secondary Current Sense Return from FET PC Boards J6 8 J7 9 Over Temperature Sense from FET PC Boards J6 9 J7 10 Over Temperature Sense from FET PC Boards J6 10 J...

Page 63: ...Master Enable Signal to Logic PC Board J4 11 J9 12 Master Enable Signal from Logic PC Board J4 12 J9 13 Return for PWM Enable Signal to Logic PC Board J4 13 J9 14 PWM Enable Signal from Logic PC Board...

Page 64: ...to Move J12 9 Not Used J12 10 OK to Move RTN TO J22 14 Torch Control OK to Move RTN J13 1 Torch Switch Filter out to J5 8 Logic Board Torch Sw J13 2 Torch Switch Filter gnd out to J5 9 Logic Board Tor...

Page 65: ...23 E9 PS to E18 Upper Fet Module E10 PS to E18 Upper Fet Module E20 From E22 to PCR Pin 2 E22 From Pilot Choke to E20 E23 C4 Rtn for Pilot Voltage Twisted with Pilot RTN from E8 E24 Pilot RTN from Sta...

Page 66: ...Logic PC Board J5 1 J11 2 Return from Logic PC Board J5 2 J11 3 36 VAC from Logic PC Board J5 3 J11 4 CD Enable Signal from Logic PC Board J5 4 J11 5 Return for CD Enable Signal from Logic PC Board J...

Page 67: ...t used CGND Chassis Ground to Chassis Ground R2 Rectifier to Rectifier G SCR Gate to SCR Gate SCR Cathode Module Output to the Cap Board E25 Rectifier Module Output to the Cap Board E26 AC1 AC Input P...

Page 68: ...IX FET PC BOARD LAYOUT Solder Side Of PC Board A 01387 Component Side Of PC Board E19 E18 E14 J6 G1 E14 E17 XFMR SEC E17 E18 E19 OUTPUT OUTPUT E15 MAIN XFMR PRI MAIN XFMR PRI E14 E16 MAIN XFMR SEC 10...

Page 69: ...ate Drive Board upper J7 6 Lower J8 6 J6 7 SEC CURRENT SENSE to the Gate Drive Board upper J7 7 Lower J8 7 J6 8 SEC CURRENT SENSE RTN to the Gate Drive Board upper J7 8 Lower J8 8 J6 9 OVER TEMP RTN t...

Page 70: ...tor PC Board Signals E1B Positve Rail to FET Board E1C Positve Rail to FET Board E2B Negative Rail to FET Board E2C Negative Rail to FET Board E1A Positive Input from Input Board SCR Cathode E2A Negat...

Page 71: ...M Auxiliary Transformer Outputs 115 VAC J1 1 2 3 5 6 36 VAC J3 3 1 2 4 ON OFF Switch 1 3 2 J5 CD PC Board 3 1 J4 5 7 4 2 8 6 Logic PC Board 3 1 J9 5 7 4 2 8 6 36 VAC GND IN IN OUT OUT Voltage Check Ci...

Page 72: ...APPENDIX 66 Manual 0 2587 APPENDIX XII SYSTEM SCHEMATIC A 01370 1 2 1 2...

Page 73: ...Manual 0 2587 67 APPENDIX A 01370 B EC 8055 HAS 11 23 98...

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